REACTION INJECTION MOLDING

(RIM)
RIM PROCESS

 two highly reactive liquid monomers are carefully

metered, brought together in a mixhead, and
immediately injected into a heated mold under low
pressure
RIM VARIATIONS

 neat resin
 reinforced reaction injection molding (RRIM) - fillers
(including chopped glass, carbon/graphite fibers)
can be incorporated into one or both monomers
 structural reaction injection molding (SRIM) -
reinforcement placed in mold before injecting the
reactive liquid monomers
SCHEMATIC OF RIM PROCESS
RESINS USED IN RIM PROCESS

 polyurethane (most common)

– two liquid monomer components
 polyol
 isocyanate
– high CTE (unreinforced 60 - 90 x 10-6 in/in/°F)
– low modulus (flexural, 20 - 300 ksi)
 dicyclopentadiene (dcpd)
– see Telene website
REINFORCEMENT USED IN RIM
PROCESS

 RRIM
– chopped, milled fibers (glass, carbon/graphite)
– usually added to polyol
 SRIM
– glass, carbon/graphite, aramid
– fabric (woven, unidirectional, multiaxial)
– mat
– preform
RIM PROCESS AND EQUIPMENT

 day tanks
– store unfilled components and filled (reinforced)
components
– slowly and continuously agitate by mixing impellers to
prevent settling of fibers
– may have heating jackets for temp control
– pressurized at 15 - 60 psi
 metering cylinders fill with components from day
tanks
– components could be moved directly from the pressurized
tanks with air pressure, however usually transferred with
the assistance of feeder pumps
– feeder pumps can provide continuous recirculation
(maintain filler in suspension and uniform temp)
MIXING OF COMPONENTS

 after metering cylinders filled, they are driven forward by hydraulic

pressure to deliver components to mixhead at a known rate (delivery
of the two components must be closely synchronized to ensure a
uniform reaction and consistent properties in cured part)
 during first part of plunger travel, valve to mixing chamber is closed -
components are recirculated through head into return lines and back
to day tanks
 after preliminary recirculation - mixhead valve is opened,
components enter the chamber to be mixed
 mix chamber is usually small cylinder - components enter from
opposite sides of chamber
 mixhead is designed to develop turbulence in the mix chamber to
intimately mix the two components
 turbulence created by stream impingement at high pressure (1,500 -
3,000 psi)
 streams should have equal momentum at the time they meet
FILLING THE MOLD

 after metering the shot, mixhead valve is closed,

components recirculated back into day tanks
 metered shot is cleared from mixing chamber by a
close fitting ram and flows directly into mold (no
solvent flush required)
 mold normally filled from bottom so air can easily
push out ahead of flow
 shot fills mold to about 90% and expansion during
chemical reaction of the polyol and isocyanate
completes the fill
CURING AND DEMOLDING

 components react and gel within 2 - 10 secs from

the start of injection
 mold remains closed for a period of time to allow
sufficient cure so part can be removed and handled
without damage (30 - 90 secs)
 knockout pins, automatic slides, or pneumatic
devices in the mold used to assist with demolding
 for small flexible parts may use rubber spatula to
pry part loose or insert air nozzle and blow off
 for most resin formulations, parts are post-cured in
an oven
ADVANTAGES/DISADVANTAGES OF RIM
PROCESS

 many of the same advantages/disadvantages as RTM process

 differences with RTM process
– RIM resin builds viscosity rapidly (higher average viscosity during
mold filling)
 applications must be simple geometries
 SRIM preform must be less complex and lower in reinforcement
content
 parts do not normally flash out of mold parting line sufficiently to
require sealing beyond metal land area or a pinch off around
perimeter of part (low viscosity of RTM resin requires gasket or o-
ring)
– highly reactive nature of RIM resin systems leads to cycle times
currently faster than achieved with RTM process
– mix ratios of RIM resin systems nearly 1:1 in volume
 ideally suited to impingement mixing process
 self-cleaning mix element
 RTM ratios (as high as 100:1 by volume) require mixing in a static
mixer and subsequent solvent flush